Kistler 4501A Owner's manual

Instruction

Manual

Rotating Torque Sensor

Type 4501A…

Version Q/QA

(with standard square

connections)

Version R

(with shaft ends)

Version H/HA

(with standard

hexagon connections)

4501A_002-406e-10.18

Foreword

4501A_002-406e-10.18 Page 1

Foreword

This manual applies to the rotating torque sensor Type

4501A… .

The instruction manual must be kept on hand for future

use, and must be available at the site of implementation of

the NC joining system, as needed.

The specifications in this manual can change at any time

without prior notification. Kistler reserves the right to

improve and to change the product for the purpose of

technical progress without the obligation to inform persons

and organizations as the result of such changes.

Original language of these operating instructions: German

Kistler Group

Eulachstrasse 22

8408 Winterthur

Switzerland

Phone +41 52-224 11 11

Fax +41 52-224 14 14

[email protected]

www.kistler.com

Rotating Torque Sensor, Type 4501A…

Page 2 4501A_002-406e-10.18

Content

1.Introduction ................................................................................................................................... 3

2.Important Information .................................................................................................................... 4

2.1Disposal Instructions for Electrical and Electronic Equipment ................................................ 4

2.2Symbols Used ....................................................................................................................... 4

3.Application and Key Features ......................................................................................................... 5

4.Description ..................................................................................................................................... 6

4.1Mechanical Design ............................................................................................................... 6

4.2Electrical Design ................................................................................................................... 7

4.3Rotation Angle Measuring System (Version QA and HA only) ............................................. 8

4.4Adjustment for Angle-pulse Output (version QA only) ........................................................ 9

5.Electrical Connections .................................................................................................................. 10

5.1Description of Interfaces ..................................................................................................... 11

5.1.1Versions Q/R/H .................................................................................................... 11

5.1.2Connection Cable Q/R/H ...................................................................................... 11

5.1.2.1Cable Diagram with Plugs on Both Sides Mat. No.: 18008930, Type

KSM071860-5, Versions Q/R/H ............................................................ 11

5.1.2.2Cable Diagram, Plug (Transducer), Open Ends Mat. No.: 18008939, Type

KSM103820-5, Versions Q/R/H ............................................................ 12

5.1.3Versions QA/HA ................................................................................................... 12

5.1.4Connection Cables QA, HA ................................................................................... 13

5.1.4.1Cable Diagram with Plugs on Both Sides, Mat. No.: 18008955, Type

KSM170690-5, Version QA and HA ...................................................... 13

5.1.4.2Cable Diagram, Plug (Transducer), Open Ends, Mat. No.: 18008958,

Type KSM183150-5, Version QA and HA.............................................. 14

5.1.5Plug Series MIL, CA-Bayonet ................................................................................. 14

5.1.6Cable Diagram, Plug, Open Ends Mat. No.: 18025415, Type KSM007331, MIL/CA-

Bayonet ................................................................................................................. 15

5.2Installing the Signal Lead .................................................................................................... 16

6.Using the Torque Sensor .............................................................................................................. 17

6.1Versions Q, QA, H, HA ...................................................................................................... 17

6.2Version R ............................................................................................................................ 18

7.Static Calibration.......................................................................................................................... 19

7.1Making a Simple Calibration Device ................................................................................... 19

7.2Calculation Example for Lever Arm Length ......................................................................... 20

8.Maintenance ................................................................................................................................ 21

9.Repairs ......................................................................................................................................... 22

10.Ordering Key ................................................................................................................................ 23

11.Index ............................................................................................................................................ 24

Total Pages 26

Introduction

4501A_002-406e-10.18 Seite 3

1. Introduction

Please take the time to thoroughly read this instruction

manual. It will help you with the installation, maintenance,

and use of this product.

To the extent permitted by law Kistler does not accept any

liability if this instruction manual is not followed or

products other than those listed under Accessories are

used.

Kistler offers a wide range of products for use in measuring

technology:

 Piezoelectric sensors for measuring force, torque, strain,

pressure, acceleration, shock, vibration and acoustic-

emission

 Strain gage sensor systems for measuring force and

torque

 Piezoresistive pressure sensors and transmitters

 Signal conditioners, indicators and calibrators

 Electronic control and monitoring systems as well as

software for specific measurement applications

 Data transmission modules (telemetry)

 Electromechanical NC joining modules and force-

displacement monitors

 Test bed systems for electric motors and gear units for

laboratory, manufacturing, and quality assurance

Kistler also develops and produces measuring solutions for

the application fields engines, vehicles, manufacturing,

plastics and biomechanics sectors.

Our product and application brochures will provide you

with an overview of our product range. Detailed data

sheets are available for almost all products.

If you need additional help beyond what can be found

either online or in this manual, please contact Kistler's

extensive support organization.

Rotating Torque Sensor, Type 4501A…

Page 4 4501A_002-406e-10.18

2. Important Information

2.1 Disposal Instructions for Electrical and Electronic Equipment

Do not discard old electronic instruments in municipal

trash. For disposal at end of life, please return this

product to an authorized local electronic waste disposal

service or contact the nearest Kistler Instrument sales

office for return instructions.

2.2 Symbols Used

NOTE

This symbol indicates instructions that enable more

effective and more economic use of the NC joining

module.

Application and Key Features

4501A_002-406e-10.18 Seite 5

3. Application and Key Features

 Torque sensor with strain gages

 Signal transfer by slip rings

 Measurement of constant and variable torque

 Measurement of torque from the rotating shaft

 Integrated system for rotation angle measurement (only

version QA)

 Suitable for laboratory use and quality control

 Ideal for use with power tools

 Primarily suitable for low speed ranges

 Suitable for momentary measurement of torque (inter-

mittent duty)

Fig. 1: Rotating torque sensor

Tor

q

ue

Rotation angle

11 ... 26 V

Measuring electronics

Strain gage

measuring shaft

Rotating Torque Sensor, Type 4501A…

Page 6 4501A_002-406e-10.18

4. Description

4.1 Mechanical Design

Torque sensors Type 4501A… comprise a rotating shaft

mounted on bearings inside a housing. The shaft has a

necked section - called the torsion zone - to which strain

gages are attached and connected in a full bridge circuit.

Slip rings and brushes provide the link between rotor and

housing with two slip rings carrying the electric power

supply to the strain gages on the rotating shaft. Two other

slip rings serve to transfer the measuring signals from the

rotating shaft to the stationary housing. The full bridge

circuit is connected directly through the slip rings and

brushes to the lead connector which is mounted on the

housing of the torque sensor.

In version QA torque sensors an optical rotation angle

measurement system is integrated. It consists of a pulse

disk on the rotating shaft with 360 light-dark stripes. Two

light barriers are installed into the stator. Inside the torque

sensor there is a small electronics for processing of the

angle pulses.

Fig. 2: Mechanical design rotating torque sensor

Type 4501A...

Bearing

Brushes

Lead connector

Shaf

t

Bearing

Slip rings

Torsion zone

Strain gages

Square socket

(version Q)

or hexagon socket

(version H)

or shaft end with

feather key slots

(version R)

Square end

(version Q)

or hexagon end

(version H)

or shaft end with

feather key slots

(version R)

Housing

Rotation angle

measuring system

(only version QA/HA)

Description

4501A_002-406e-10.18 Seite 7

4.2 Electrical Design

Fig. 3: Electrical design

 R1 ... R4 = Gages for measuring mechanical strain

 S1 ... S4 = Slip rings with brushes

Version Q/R/H:

Version QA:

Version H (special):

Rotating Torque Sensor, Type 4501A…

Page 8 4501A_002-406e-10.18

4.3 Rotation Angle Measuring System (Version QA and HA only)

Fig. 4: Diagram showing the design of the rotation

angle measuring system

1 Rotating shaft

2 Pulse disk

3 Forked light barrier with LED and photo diode

4 Operation amplifier

Features

 360 light-dark stripes on the pulse disk

 Two forked light barriers shifted by phase angle 90°

 Pulse number proportional to the rotation angle

Description

4501A_002-406e-10.18 Seite 9

4.4 Adjustment for Angle-pulse Output (version QA only)

With drive on quare socket sense of rotation right

Fig. 5: Adjustment for angle-pulse output

Out

p

ut Pin H

Out

p

ut Pin G

Sense of rotation

W

Label M for

measuring side.

Side with bearings

Size Q/QA Size R

Drive side

Rotating Torque Sensor, Type 4501A…

Page 10 4501A_002-406e-10.18

5. Electrical Connections

Fig. 6: Electrical connections

 Shielded lead of 0,25 mm²

(version X: 0,14 mm2) cross section

 Factory-calibrated with 5 m of lead.

A change in lead of 2,5 m will cause an error of

approximately 1 %

Shielded lead

Lead connecto

r

To

p

ower su

pp

ly unit and dis

p

lay

Torque sensor (all versions)

Electrical Connections

4501A_002-406e-10.18 Seite 11

white Supplyvoltage‐6Vwhite

brown Supplyvoltage+6Vbrown

yellow Measuring+yellow

grey Measuring‐ grey

green Ext.Control green

4 4

5 5

6 6

1 1

2 2

3 3

Standardlength5m

Plugbox6pin

Art.No.:KSM000823

Controlcableflexible

LIYCY5x0,25transparent

Art.‐No.:KSM002148

ColorcodetoDIN47100

Plug6pin

Art.No.:KSM000822

(

Sensor

Electronic

5.1 Description of Interfaces

5.1.1 Versions Q/R/H

Function PIN Description Top view built-in plug

− Power supply 1 e.g. 6 VDC 



+ Power supply 2 e.g. 6 VDC

Shield 3 Not connected

+ Measuring signal 4 2 mV/V approx. 350 Ω*

− Measuring signal 5 2 mV/V approx. 350 Ω*

− Power supply

(Calibration voltage) 6 100 % calibration,

causes 100 % signal

* Customized, see calibration certificate

5.1.2 Connection Cable Q/R/H

5.1.2.1 Cable Diagram with Plugs on Both Sides Mat. No.: 18008930, Type KSM071860-5, Versions

Q/R/H

Fig. 7: Cable diagram connection cable

Rotating Torque Sensor, Type 4501A…

Page 12 4501A_002-406e-10.18

white Supplyvoltage‐6Vwhite

brown Supplyvoltage+6Vbrown

yellow Measuring+ yellow

grey Measuring‐ grey

green Ext.Control green

5

6

3

4

Openends,

tinned

1

2

Standardlength5m

Plug6pin

Art.No.:KSM000822

Controlcableflexible

LIYCY5x0,25transparent

Art.‐No.:KSM002148

ColorcodetoDIN47100

(

Sensor

Electronic

5.1.2.2 Cable Diagram, Plug (Transducer), Open Ends Mat. No.: 18008939, Type KSM103820-5,

Versions Q/R/H

Fig. 8: Cable diagram, plug (transducer), open ends

5.1.3 Versions QA/HA

Function PIN Description Top view built-in plug

− Power supply A Strain gage full bridge

+ Power supply B

+ Measuring signal output C

− Measuring signal output D

Angle 0 V E Rotation angle pulses

Angle +5 V ±10 % F

Pulse l, leading, TTL G

Pulse r, lagging, TTL H 0 V

Power supply

(Calibration voltage) K 100 % calibration, causes

100 % signal

Shield N Not connected

Electrical Connections

4501A_002-406e-10.18 Seite 13

pink Supplyvoltagetorque‐ pink

black Supplyvoltagetorque+black

red Signaloutputtorque+red

blue Signaloutputtorque‐ blue

violet 0VAngleofrotation violet

brown 0VAngleofrotation brown

yellow +5VAngleofrotation yellow

white

/

green Angleimpulse1leading white

/

green

white

/

brown Angleimpulse2lagging white

/

brown

white Control white

green 0VAngle green

grey 0VAngle grey

black Shield black

Case

H H

K K

J J

F F

G G

C C

D D

E E

A A

B B

Controlcableflexible

LIYCY12x0,14transparent

Art.‐No.:KSM002148

Plugbox12pin

Art.No.:KSM000703

Plug12pin

Art.No.:KSM000704

Standardlength5m

M M

Case

(

Sensor

(

Electronic

5.1.4 Connection Cables QA, HA

5.1.4.1 Cable Diagram with Plugs on Both Sides, Mat. No.: 18008955, Type KSM170690-5, Version

QA and HA

Fig. 9: Cable diagram connection cable

Rotating Torque Sensor, Type 4501A…

Page 14 4501A_002-406e-10.18

pink Supplyvoltagetorque‐ pink

black Supplyvoltagetorque+black

red Signaloutputtorque+red

blue Signaloutputtorque‐ blue

violet 0VAngleofrotation violet

brown 0VAngleofrotation brown

yellow +5VAngleofrotation yellow

white

/

green Angleimpulse1leading white

/

green

white

/

brown Angleimpulse2lagging white

/

brown

white Control white

green 0VAngle green

grey 0VAngle grey

black Shield black

Case

M

J

H

K

F

G

E

C

D

B

Standardlength5m

Plugbox12pin

Art.No.:KSM000703

Controlcableflexible

LIYCY12x0,14transparent

Art.‐No.:KSM002146

Openends,

tinned

A

(

Sensor

(

Electronic

5.1.4.2 Cable Diagram, Plug (Transducer), Open Ends, Mat. No.: 18008958, Type KSM183150-5,

Version QA and HA

Fig. 10: Cable diagram, plug (transducer), open ends

5.1.5 Plug Series MIL, CA-Bayonet

Function PIN Description Top view built-in plug

+ Power supply A z.B. +6 VDC 



− Power supply B z.B. −6 VDC

− Output (measuring signal) C z.B. 2 mV/V ca. 350 Ω*

+ Output (measuring signal) D z.B. 2 mV/V ca. 350 Ω*

Shield E Im Sensor nicht belegt

− 100 % control (supply)

(Calibration voltage) F 100 % Kalibrierung,

d.h. 100 % Messsignal

* Customized, see calibration certificate

Electrical Connections

4501A_002-406e-10.18 Seite 15

white Supplyvoltage+6Vwhite

B brown Supplyvoltage‐6Vbrown

yellow Output‐ yellow

grey Output+grey

green 100%Control green

free

E

D

F

C

Openends,

tinned

A

Standardlength5m

Plugbox6pin

Art.No.:KSM002265

Controlcableflexible

LIYCY5x0,25transparent

Art.‐No.:KSM002148

Farbcoden.DIN47100

(

Sensor

Electronic

(

5.1.6 Cable Diagram, Plug, Open Ends Mat. No.: 18025415, Type KSM007331,

MIL/CA-Bayonet

Fig. 11: Cable diagram, plug, open ends

Rotating Torque Sensor, Type 4501A…

Page 16 4501A_002-406e-10.18

5.2 Installing the Signal Lead

 Do not run the lead parallel to power cables or control

circuits.

 Do not place the lead close to equipment producing

strong electromagnetic fields, e.g. transformers, wel-

ders, contactors, electric motors, etc.

 If such situations cannot be avoided, run the lead inside

earthed steel conduit.

 Excess lengths should be prevented. If it isn’t possible to

avoid, then do not lay excess lengths in closed loops.

Fig. 12: Laying of the measuring cable

Risk to couple in EMC noises into the

measuring sensor cable

To reduce the inductive areas it’s

recommended to laying the measuring

sensor cable in bifilar form

Measuring cable



!

Cable tunnel Measuring cable Cable tunnel

Using the Torque Sensor

4501A_002-406e-10.18 Seite 17

6. Using the Torque Sensor

6.1 Versions Q, QA, H, HA

 Torque sensors of version Q and QA have square

connections for plug-in tools acc. to DIN 3121

 Torque sensor of version H have hexagon connections

acc. to DIN 3126, form E/F

 The torque sensors are plugged on to the drive spindle

as shown below

Application examples:

Fig. 13: Application examples versions Q/QA and

H/HA

Version

Q/QA Version

H/HA

Motor/

el. or

pneum.

wrench

Tor

q

uemete

r

model SD

Lead

connector

Socket s

p

anner/bi

t

Lead

connector

Rotating Torque Sensor, Type 4501A…

Page 18 4501A_002-406e-10.18

6.2 Version R

The tor

q

ue sensor is ada

p

ted to the measuring a

pp

li-

cation by couplings.

For a free floating installation we recommend two

torsionally rigid half couplings.

Application example:

Fig. 14: Application example version R

Tes

t

S

p

ecimen Engine Tor

q

ue Senso

r

Static Calibration

4501A_002-406e-10.18 Seite 19

7. Static Calibration

This

p

rocedure re

q

uires the use of a calibration device

with a lever arm and weights for producing specific

values of torque.

The calibration procedure is as follows

 Apply the rated value of torque to the torque sensor

and then remove it again

 Adjust the zero reading accurately

 Apply a known value of torque to the torque sensor.

 Adjust the displayed reading to the corresponding value

Plotting a calibration curve

 Calibrate the torque sensor as described above.

 Apply torque in 1/10 steps up to the full rated value

and then remove it again in the same way.

A delay of at least 30 seconds must be allowed

between the individual 1/10 steps so that each reading

can stabilize before it is recorded

7.1 Making a Simple Calibration Device

Fig. 15: Calibration device

Weigh

t

(calibrated)

Tor

q

ue Senso

r

Lever arm Lever arm

Cou

p

ling Cou

p

ling

Counter bearing Lever arm bearing

(duplex)

Lever arm bearing

Cou

p

ling = Loose hal

f

-cou

p

lings Ty

p

e 2301A… or Ty

p

e 2302A…

or Type 2303A…

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Kistler 4501A Owner's manual

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